Elbow Terminal Assembly for 90-Degree Encapsulated Stator Wiring
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Solution Overview
Problem
Existing terminal assemblies for electric submersible pumps (ESPs) face challenges in efficiently connecting lead wires to magnet wires at a 90-degree angle, which complicates assembly and requires additional space and encapsulant material.
Innovation Solution
A terminal assembly featuring an elbow terminal with a 90-degree configuration, an insulating tube made of structural dielectric material, and a centralizing sleeve, which allows for easier assembly and reduced axial space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional terminal assemblies use straight connectors for 90-degree wire connections, then the assembly requires additional space and more encapsulant material, but the elbow terminal configuration reduces space requirements and material usage
Solution Approach 1:
The terminal assembly transitions from a linear straight connector to a three-dimensional elbow configuration with 90-degree angled arms. This dimensional change allows the terminal to accommodate perpendicular wire connections without requiring additional axial space, effectively solving the space constraint problem while maintaining connection functionality.
Solution Approach 2:
The terminal is divided into multiple segmented arms (first arm and second arm at 90 degrees) rather than a single straight connector. This segmentation enables each arm to handle specific wire connections independently, reducing the overall space requirement and encapsulant material needed while simplifying the assembly process.
2Ease of manufacture
If traditional terminal assemblies require additional space for 90-degree connections, then the assembly process becomes more complex and requires more materials, but the elbow terminal design simplifies assembly and reduces material requirements
Solution Approach 1:
The elbow terminal merges the connection functions of multiple wires into a single integrated component with angled arms. This consolidation eliminates the need for separate connectors or additional space for 90-degree bends, thereby reducing encapsulant material requirements while simplifying the assembly process into fewer steps.
Solution Approach 2:
The terminal is pre-configured with 90-degree angled arms during manufacturing, eliminating the need for field modifications or additional assembly steps to create perpendicular connections. This preliminary configuration reduces both assembly complexity and material requirements by having the geometry prepared in advance.
3Reliability
If the insulating tube is made from structural dielectric material, then heat conduction is enhanced, but the material selection is constrained to specific high-performance polymers
Solution Approach 1:
The insulating tube is constructed from composite structural dielectric materials that combine polymer matrices with conductive fillers or reinforced structures. This composite approach enables the material to simultaneously provide electrical insulation and enhanced heat conduction pathways, achieving improved thermal management while maintaining dielectric properties.
Solution Approach 2:
The material properties of the insulating tube are optimized by adjusting parameters such as filler content, cross-linking density, or molecular structure of the polymer. These parameter changes enable the material to achieve superior heat conduction capability within the constraints of dielectric requirements, balancing thermal performance with electrical insulation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The terminal assembly simplifies the connection process, reduces the need for additional axial space and encapsulant material, and enhances ease of assembly and heat conduction.
Implementation Method 1
an insulating tube, wherein the first arm of the elbow terminal extends within the insulating tube and the second arm of the elbow terminal protrudes from the insulating tube
Implementation Method 2
The insulating tube can be made of a structural dielectric material based on poly aryl ether ketone chemistry
Data Source
AI summary
A terminal assembly for an encapsulated stator is provided. The terminal assembly includes an elbow terminal and an insulating tube. The terminal assembly allows for joining of magnet wire and lead wire at a 90 degree angle. A terminal assembly for an ESP motor head is provided. The terminal assembly includes a terminal, an insulation tube, and a sleeve. The insulation tube is disposed in the motor head pothole. The terminal is disposed within the insulation tube. An end of the terminal configured to receive a lead wire includes internal threads. The threads allow for accommodation of various lengths of lead wires extending from the stator.